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Friction stir spot welding (FSSW) was performed for joining of an aluminum alloy sheet to a steel sheet. A 6022 aluminum alloy sheet, a non-plated steel and four kinds of plated steel sheets were prepared. They were plated by pure zinc (GI), zinc alloy (ZAM), Al-Si alloy (AS) and zinc alloy including Fe (GA). The melting temperature of each plated layer was 420, 330, 640 and 880 C. The aluminum alloy sheet was overlapped on the steel sheet. A rotating tool was inserted from the aluminum alloy sheet side and the probe tip was kept at the position of 0.2 mm above the lapped interface for 3 s. Temperature change at the welding interface was measured during FSSW by using thermocouples which were located at the joint interface below the rotating tool. The maximum operating temperature was 430 C. It was found that interface morphology, strength and joining area of the joint varied depending on whether melting temperature of the plate layer was higher or lower than the maximum operating temperature. Large joint strength and joining area were obtained for the steel sheet with the low melting temperature of plated layer. In this case, the original plated layer was removed from the interface during FSSW and aluminum/steel interface with a thin intermediate layer was observed. [doi:10.2320/matertrans.L-M2011811]

Microstructure and Joint Strength of Friction Stir Spot Welded 6022 Aluminum Alloy Sheets and Plated Steel Sheets